Multi-purpose transport and flooring structures, and associated methods of manufacture

ABSTRACT

A pallet cap for covering and connecting with at least one existing pallet includes a reinforced platform having a flat top surface and a bottom surface opposite the top surface. Four vertical, peripheral edges connect the top and bottom surfaces. Three or more of the edges form at least one edge extension continuing outward from the reinforced platform, and at least one edge notch proximate the edge extension and recessed from the edge extension. At least one notched corner is formed by distal edge extensions of edges meeting perpendicular to one another. A plurality of retaining walls extend downward from the bottom surface of the platform and define the edge notches, proximate a junction of the platform and the edge extensions, for securing the pallet cap over a shipping pallet. Multiple caps may be connected to form an expandable raised flooring system or other structures.

RELATED APPLICATIONS

This applications claims priority of U.S. Provisional Patent ApplicationNo. 61/832,000, filed Jun. 6, 2013, which is incorporated herein byreference.

FIELD OF THE INVENTION

The present disclosure relates to flooring and to shipping, and moreparticularly to the combination of multiple shipping pallets or palletcaps for additional purposes, such as formation of an expandable, raisedflooring system.

BACKGROUND

When transporting goods via rail, airplane, trailer truck, or by cargoship, packaging, containment and support of the goods is of paramountimportance. Pallets are often used to support goods, alone or withinadditional transport structures, such as boxes or crates, duringtransport. Pallets themselves are transport-specific goods, manufacturedspecifically for use during transport.

The cost of pallets is assumed by the shipper, because the palletsthemselves are generally not sold as goods upon arrival. Pallets alsoincrease fuel cost of the shipper, as they add weight to cargo and thusincrease the amount of fuel needed for transport. Furthermore, thisadditional weight can at times reduce the overall amount of goods thatmay be transported by vehicles; a point especially true of aircraft andwatercraft transport. Finally, in their use of forest resources, palletscarry a significant environmental burden. Despite efforts to repair andre-use wooden pallets, they are often disposed of after use, thusrequiring additional resources to create more pallets, and increasingthe environmental costs of the transport industry.

In summary, as a single-purpose shipping good, conventional pallets havea higher than desirable environmental cost and increase shipper-assumedcosts and fuel costs, while reducing the total amount of saleable goodsthat may be transported as cargo.

SUMMARY

There is a need for a multipurpose transport and flooring structure thatcan be repurposed after use in transport. Such repurposing extends theuseful life and commercial value of a shipping pallet and reduces itsoverall environmental cost through repurposing. The multipurposetransport and flooring structures disclosed herein address theabove-mentioned needs. The disclosed structures provide support forgoods during transport while also being reusable/saleable aftertransport, for example as raised flooring, as a structural member, or asa crate, lockable box or component thereof.

In one embodiment, a multipurpose shipping pallet includes a reinforcedplatform having a top surface for supporting goods and a bottom surfaceopposite the top surface. A plurality of individual footings extend fromthe bottom surface, for raising and supporting the platform aboveground. Fastening supports configured with at least one edge of thepallet accept one or more fasteners to hingedly secure the pallet withanother pallet, at the edge. The fasteners may be compression-assistedslide bolts. At least one of the individual footings includes anadjustable base opposite the bottom surface of the platform, tofacilitate supporting the pallet on an uneven surface.

In one embodiment, a pallet cap for covering and connecting with atleast one pallet includes a reinforced platform having a substantiallyflat top surface and a bottom surface opposite the top surface. Fourperipheral edges extend from and connect the top and bottom surfaces.Three or more of the edges each form at least one edge extensioncontinuing outward from the reinforced platform, and at least one edgenotch proximate the edge extension and recessed from the edge extension.At least one notched corner is formed by distal edge extensions of edgesmeeting perpendicular to one another. A plurality of retaining wallsextend downward from the bottom surface of the platform and define theedge notches, proximate a junction of the platform and the edgeextensions, for securing the pallet cap over a shipping pallet.

In one embodiment, an expandable raised flooring system includes aplurality of pallet caps, each having (a) a reinforced platform with aflat top surface and a bottom surface opposite the top surface, and (b)four peripheral edges, three or more of which form at least one edgeextension and at least one edge notch having rear retaining wallsextending downward from the bottom surface of the pallet cap, forfitting about a shipping pallet and/or raising the cap above a groundsurface. Edge extensions of a first of the plurality of pallet caps fitwithin edge notches of a second of the plurality of pallet caps, toconnect the first and second caps.

In one embodiment, a method of converting shipping pallet caps intoraised flooring includes positioning a plurality of pallet caps over asupporting surface and interconnecting the pallet caps via complementarylock and key features of the pallet caps. A plurality of apertures areprovided through the pallet caps, to prevent moisture accumulation atopthe pallet caps and/or to secure the interconnected pallet caps togethervia fasteners. A non-skid top surface is provided on the pallet caps, toprevent users of the raised flooring system from slipping.

In one embodiment, a method of manufacturing a pallet cap includesforming a reinforced platform including a top surface, an opposingbottom surface and four edges, each edge including at least one edgeextension, at least one edge notch and sidewalls separating and definingadjacent notches and extensions. Each extension includes (a) ahorizontal plate extending from and in the plane of the top surface ofthe platform, and (b) a downwardly-extending outer wall at a distal endof the horizontal plate, the downwardly-extending outer wall forming anobtuse angle with a bottom surface of the horizontal plate and relativeto the bottom surface of the platform. Each edge notch includes a rearretaining wall extending downward from the platform at an obtuse anglerelative to the platform, and a lower edge plate extending outward froma bottom portion of the rear retaining wall.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a pallet cap for covering andattaching with a pallet, according to an embodiment.

FIG. 2 is a top view of the pallet cap of FIG. 1.

FIG. 3 is a top view of the pallet cap of FIGS. 1 and 2, detailing atextured top surface, according to an embodiment.

FIG. 4 is an enlarged view of a portion of a connecting edge of thepallet cap of FIG. 3.

FIG. 5 is a perspective view of two pallet caps aligned prior to joiningby their connecting edges, according to an embodiment.

FIG. 6 is an enlarged view illustrating alignment of the pallet caps ofFIG. 5, prior to joining.

FIG. 7 is a perspective view showing the pallet caps of FIGS. 5 and 6,joined together.

FIG. 8 is an enlarged view illustrating alignment of the pallet caps ofFIG. 7 when joined together.

FIG. 9 is an enlarged view illustrating attachment of the pallet caps ofFIGS. 5-8 with a strip fastener, according to an embodiment.

FIG. 10 is an enlarged view showing a hook-and-loop fastener arrangementapplied to the pallet caps of FIGS. 5-8, according to an embodiment.

FIG. 11 shows a complimentary strip of hook-and-loop fastener appliedover the arrangement of FIG. 10.

FIG. 12 is a bottom perspective view of the pallet cap of FIG. 1.

FIG. 13 is a top, perspective view of a fold-out pallet cap in a foldedconfiguration, according to an embodiment.

FIG. 14 is a top, perspective view showing the fold-out pallet cap ofFIG. 13 in a partially unfolded configuration.

FIG. 15 is a top, perspective view of the fold-out pallet cap of FIG. 13in a fully unfolded configuration, positioned with a series of pallets,according to an embodiment.

FIG. 16 is a cross-sectional view illustrating fixation of two adjacentpallet caps by a bolt, according to an embodiment.

FIG. 17 is a cross-sectional view illustrating fixation of two adjacentpallet caps by a joining material, according to an embodiment.

FIG. 18 is a cross-sectional view illustrating fixation of two adjacentpallet caps by complementary features of the caps, according to anembodiment.

FIG. 19 is a cross-sectional view showing adjacent and connected palletcaps overlying a supporting/insulating structure, according to anembodiment.

FIG. 20 is a cross-sectional view showing adjacent and connected palletcaps overlying a supporting/insulating structure upon a ground surface,according to an embodiment.

FIG. 21 is a cross-sectional view showing adjacent and connected palletcaps overlying boxes on a ground surface, according to an embodiment.

FIG. 22 is a cross-sectional view showing adjacent pallet caps connectedby a tie fastener and overlying a supporting/insulating structure,according to an embodiment.

FIG. 23 is a cross-sectional view illustrating attachment of connectedpallet caps to lumber, according to an embodiment.

FIG. 24 is a cross-sectional view illustrating attachment of connectedpallet caps to a pole, according to an embodiment.

FIG. 25 is a cross-sectional view illustrating attachment of connectedpallet caps to timber, according to an embodiment.

FIG. 26 is a perspective view illustrating attachment of a plurality ofpallet caps to structural members of a roof, according to an embodiment.

FIG. 27 is a cross-sectional view illustrating attachment of a pluralityof pallet caps to structural members of a wall, according to anembodiment.

FIG. 28 is a cross-sectional view illustrating alternate connection oftwo pallet caps to form inner and outer building surfaces.

FIG. 29 is another cross-sectional view illustrating alternateconnection of two pallet caps.

FIG. 30 is bottom, perspective view of a pallet, according to anembodiment.

FIG. 31 is a top, perspective view of the pallet of FIG. 30.

FIGS. 32A-32C illustrate a compression assisted slide-bolt as also shownin FIG. 31

FIG. 33 shows two pallets of FIG. 30 assembled together, according to anembodiment.

FIG. 34 is an exploded view of the two-pallet assembly of FIG. 1,illustrating placement of slide-bolts (see also FIG. 35) and a lock bar,for holding the assembly together.

FIG. 35 is a top, perspective view of the lock bar of FIG. 34

FIG. 36 is a bottom, perspective view of the lock bar of FIGS. 34 and35.

FIG. 37 is a bottom view of a two-pallet assembly, according to anembodiment.

FIG. 38 shows a crate assembly formed with pallets of FIG. 30, accordingto an embodiment.

FIG. 39 is an exploded view showing exemplary pallet placement in thecrate assembly of FIG. 38.

FIG. 40 shows an expandable flooring system formed of the pallets ofFIG. 30, according to an embodiment.

FIG. 41 is a cross-sectional view of the pallet of FIG. 30 through alock bar slot, according to an embodiment.

FIG. 42 is a cross-sectional view of the pallet of FIG. 30 through aslide-bolt housing, according to an embodiment.

FIG. 43 is a cross-sectional view of the pallet of FIG. 30 through anadjustable footing, according to an embodiment.

FIG. 44 is an enlarged view of components of the adjustable footing,positioned as shown in FIG. 43.

FIG. 45 illustrates motion of the adjustable footing of FIG. 43.

FIG. 46 is an enlarged view of components of the adjustable footing,positioned as shown in FIG. 45.

FIG. 47 is a reflected plan view showing the bottom of the pallet ofFIG. 30.

FIG. 48 is a top, perspective view of a pallet supporting goods,according to an embodiment.

FIG. 49 is a top, perspective view of the pallet of FIG. 48, unloadedand supporting a person.

FIG. 50 is a top, perspective view of a plurality of pallets, such asthe pallets of FIGS. 48 and 49, assembled together to form a raisedfloor, according to an embodiment.

FIG. 51 is a top, perspective view of a plurality of pallets, such asthe pallets of FIGS. 48 and 49, assembled together to form a crate,according to an embodiment.

FIG. 52 schematically illustrates opposing side alignment of twopallets, such as the pallets of FIGS. 48 and 49, showing complementaryfeatures for aligning and interlocking the pallets, according to anembodiment.

FIG. 53 is an isometric perspective view, schematically illustratinglike-side alignment of two pallets, such as the pallets of FIGS. 48 and49, showing complementary features for aligning and interlocking thepallets, according to an embodiment.

FIG. 54 shows two pallets aligned edge to edge and perpendicular to oneanother, further illustrating placement of a slide bolt within a channelformed by the aligned edges, according to an embodiment.

FIG. 55 illustrates advancement and rotation of the slide bolt withinthe channel of FIG. 54, to lock the pallets together, according to anembodiment.

FIG. 56 is a schematic side view illustrating loss of body heat into aground surface.

FIG. 57 is a schematic side view illustrating a raised flooring surface,reducing conductive heat loss of a body resting thereupon.

FIG. 58 is a schematic side view illustrating a raised flooring surfacewithin a housing unit, forming an insulative air cavity to preserve bodyheat of a body resting thereupon.

DETAILED DESCRIPTION

FIG. 1 illustrates alignment of a multipurpose transport structure 100with a pallet 10. Pallet 10 may be a pallet used in transport, or adiscarded or found pallet. FIG. 2 is a top view of transport structure100. For purposes of the following discussion, FIGS. 1 and 2 are bestviewed together.

Multipurpose transport structure 100 is also referred to hereinafter aspallet cap 100 or panel 100. Pallet cap 100 has a flat top surface 102and four edges 104. Each edge 104 features one or more edge extensionsgenerally designated as 106, and more specifically herein below. An edgenotch 108 may be formed between two edge extensions 106 along the sameedge 104. For clarity of illustration, not all extensions 106 andnotches 108 are labeled. Edges 104 that are normal to one another joinat a corner 110; whereas edge extensions 106 that are normal to oneanother join at an extended corner 112. A notched corner 114 is formedwhere two edge extensions 106 meet at a corner of pallet cap 100,separated by a corner notch 116. In one aspect, edge extensions 106 ofnotched corner 114 are in-plane with one another. Alternately, notchedcorner 114 may be formed of an upper edge extension 118 and a lower,plate-like extension 120 (described below and with reference to FIGS.5-7), of two upper extensions 118 or of two lower, plate-like extensions120.

Pallet cap 100 may be made from plastic and/or composite materials, oralternately from wood, metal or other suitably strong and rigidmaterial. Pallet cap 100 is designed to fit over a top surface 12 ofshipping pallet 10, thus providing a continuously flat surface. Intransport, pallet cap 100 and pallet 10 reinforce one another, thusproviding additional strength for supporting cargo. The flat surface ofpallet cap 100 also facilitates walking atop shipping pallets, forexample when cargo is transferred or rearranged manually, rather than bymachine.

In the field, for example at a refugee camp, pallet cap 100 may beplaced atop a shipping pallet 10, for example, one left at the camp withcargo or found at or near the camp, to provide a raised platform orflooring unit. Edges 104, extensions 106, 118 and 120 and notches 108 ofpallet cap 100 are shaped and configured to fit puzzle-like withcomplementary features (i.e., extensions 106, 118, 120, edges 104 and/ornotches 108 as arrangement dictates) of adjacent pallet caps 100, suchthat an expandable and customizable raised floor may be assembled frompallets 10 and pallet caps 100. Pallet caps 100 thus allow forappropriation of wasted pallets in the field into an expandable, raisedflooring system using a fraction of the material conventionally requiredto build a raised floor.

As shown in FIG. 3, top surface 102 of pallet cap 100 may be a non-slipsurface. Non-slip surface 102 may be formed with texture (e.g., providedby extrusions and/or indentations), for example during molding orforming of pallet cap 100, or a non-skid treatment may be applied tosurface 102 after pallet cap 100 is formed. Non-skid treatments include,but are not limited to, a textured or high-friction spray coating, anadhesive sheet or sheets, a surface treatment to roughen top surface 102and a raised or recessed pattern formed within top surface 102, forexample via injection molding, via structural foam injection molding,during thermoforming (e.g., vacuum forming), or during rotocasting orrotational molding. Peripheral edges of top surface 102 and edgeextensions 106, 118 and 120 may be left un-treated to facilitate joiningof pallets 100.

FIG. 4 is an enlarged view of area A, FIG. 3. One or more apertures 122may be formed through extension 106, for example within a slot 123. Asdescribed below, apertures 122 facilitate connection of pallet cap 100with an adjacent pallet cap.

FIG. 5 shows two adjacent pallet caps 100(1) and 100(2). FIG. 6 is anenlarged view of area B, FIG. 5, illustrating alignment of joiningfeatures of pallet caps 100(1) and 100(2). FIGS. 5 and 6 are bestconsidered together with the following description.

Lower plate-like edge extensions 120 between extensions 106/118 may beformed as extensions from a lower portion of a notch 108, and sized suchthat upon joining with an extension 106/118 of an adjoining pallet cap100, a smooth and even surface results at the junction of the palletcaps. FIGS. 5 and 6 respectively show edge extensions 106 and upper edgeextensions 118 of pallet cap 100(2) fitted atop lower plate-like edgeextensions 120 (referred to hereinafter as lower edge plates 120) ofpallet cap 100(1). Edge extensions 106 of pallet cap 100(1) fit betweennotches 108 of pallet cap 100(2). Lower edge plates 120 offer additionalsupport, reinforcement and connections between pallets 100. For example,as indicated in FIG. 6 and as further shown in FIGS. 7-9, apertures 122of edge extensions 106 align with apertures 124 of lower edge plates 120when pallet caps 100(1) and 100(2) are placed together. A fastener 20(shown as a zip tie; however, fastener 20 may alternately be anotherwire-, string- or cord-like fastener, a bolt, a screw, a nail, or astake) may then be placed through apertures 122 and 124 to secureadjacent pallet caps (i.e., 100(1) and 100(2)) together.

FIG. 7 shows pallet caps 100(1) and 100(2) fully fitted together. FIGS.8-11 are enlarged views of an area C of FIG. 7. These figures are bestviewed together with the following description.

Once pallet caps 100(1) and 100(2) are fitted snugly together (FIGS. 7and 8), a zip tie 20 (FIG. 9) may be threaded through apertures 122 and124 and secured beneath pallets 100(1) and 100)2), so as to benon-interfering with a person walking, lying or otherwise using topsurfaces 102 of the joined pallet caps. Alternately or additionally,strips of hook-and-loop fastener 22, such as that manufactured and soldunder the trademark Velcro®, are applied at adjacent ends of extensions106 of pallet caps 100(1) and 100(2), or at other adjacent pointsbetween caps 100(1) and 100(2). See FIG. 10. A complementary strip ofhook and loop fastener 24 (FIG. 11) sized to contact both adjacentstrips 22 may be applied over strips 22 and pressure applied to joinstrip 24 with strips 22 and further secure pallet caps 100(1) and 100(2)together.

FIG. 12 illustrates an underside or bottom side 126 of pallet cap 100.As shown, edge notches 108, including lower edge plates 120, form a capthickness or height h_(C) of about 1 to 4 inches, with a clearance ofabout ½ inch to 2 inches between bottom side 126 and a supportingsurface. Length and width of pallet cap 100 are sized to fit overconventional pallets, for example, over 40 inch by 48 inch pallets.Pallet cap 100 may be slightly oversized, to allow for expansion andcontraction in various weather and humidity conditions and to includeedge extensions 106 outside the perimeter of the pallet.

Height h_(C) may be consistent throughout pallet cap 100, or may be amaximum thickness of edge extensions 106 and/or notches 108.

As shown in FIG. 12, edge extensions 106 may be formed of a horizontalplate 128 extending outward from top surface 102 of a reinforcedplatform 130 (see, e.g., FIG. 7 for this surface) and a downwardlyextending outer wall 132 extending from a distal end of horizontal plate128 and forming an obtuse angle with a bottom surface of horizontalplate 128. Lower edge plates 120 may extend horizontally from a rearretaining wall 134, which extends downward from platform 130 at aplatform-to-wall junction 136. Lower edge plates 120 may be borderedlaterally by sidewalls 138, which separate and define lower edge plates120 and edge extensions 106. One or more sides of pallet 100 may includesimple and notches 108 (without horizontal lower edge plates 120). See,for example, side 142.

Rear retaining walls 134 and platform 130/bottom surface 126 form anenclosure for shipping pallets 10 (see FIG. 1), to prevent the palletsfrom slipping laterally from beneath pallet cap 100. Horizontal plates128 of edge extensions 106 may have a length l_(E) of about one inchbeyond platform 130 (and therefore, notches 108 have a depth/lower edgeplates 120 have a width of about one inch), to provide space forinterconnection of additional pallets 100 via corresponding notches 108and edge extensions 106. A height h_(E) of edge extensions 106 isequivalent to height h_(W) of rear retaining wall 134, thus providing anexpandable flooring system made from pallet caps 100 to have a level topsurface when adjacent pallet caps 100 connect with edge extensions 106,within notches 108, with downwardly extending outer walls 132 of edgeextensions 106 abutting rear retaining walls 134 and resting atop loweredge plates 120 of edge notches 108. See FIGS. 16 and 17 for lengthl_(E), height h_(E) and height h_(W).

In one aspect, rear retaining walls 134 and outer walls 132 form anobtuse angle with platform 130 (i.e., with bottom surface 126 ofplatform 130). Sidewalls 138 therefore taper outward from top surface106. The actual angle (draft angle) between walls 132, 134 and 138 andbottom surface 126 is chosen such that multiple pallet caps 100 canstack together for easy storage and transport.

FIGS. 13-15 illustrate a foldable pallet cap 200. Pallet cap 200includes interconnected tiles 203(1)-203(3) that fold along hinges orseams 205. Tiles 203 may be sized such that each fits over one shippingpallet 10; however, alternate sizes are within the scope hereof. Palletcap 200 may advantageously be customized to fit one to multiple shippingpallets or other supporting structures, by selectively unfolding tiles203. For example, pallet cap 200 may be fully folded, as shown in FIG.13, and fitted atop a single shipping pallet (i.e., pallet 10) duringtransport, and then unfolded at its destination to cover three or moreshipping pallets or supporting structures. It will be appreciated thatalthough pallet cap 200 is illustrated with three tiles 203, more orless tiles 203 and alternate positions of tiles 203 are within the scopehereof. Tiles 203 need not form a linear/rectangular structure whenunfolded, but may form a square, a cross or other shapes. For example, asix-tile pallet cap 200 includes four linearly-arranged tiles 203 withtwo tiles 203 extending from opposing open sides of one tile 203, andmay be unfolded and re-folded and fixed to form a storage crate or box.

Each tile 203 of pallet cap 200 may include features of pallet cap 100,described above. Although not all such features are called out in FIGS.13-15, upper surfaces 202, bottom surfaces 230, edge extensions 206 andlower edge plates 226 (see plates 120, above) are illustrated. These andother features of pallet cap 200 tiles 203 may be understood byreviewing the description of like features 102, 126, 106, 120, etc.,above.

FIGS. 16-18 depict alternate arrangements for fastening adjacent palletcaps 100/200 together. A screw or bolt 26 may be positioned throughaligned apertures 122 (of edge extension 106/206) and 124 (of lower edgeplate 120/226) of adjacent pallet caps 100/200, as shown in FIG. 16.Alternately or additionally, pallet caps 100/200 may be joined atadjacent edges by an adhesive 28 (FIG. 17). It will be appreciated thatwhen used in the field, adhesive 28 may be made partly or entirely ofnatural materials, including mixtures of tree sap and mud. Pallet caps100/200 may also or alternately be joined via complementary lock-and-keyfeatures. For example, as shown in FIG. 18, lower edge plate 120 forms adistal extension 144, and a trough 146 between distal extension 144 andrear wall 134. Trough 146 is sized to accept a lateral extension 148 ofadjacent pallet cap 100(1). It will be appreciated that alternatelock-and-key features, such as various male and female members, slideconnections, hooks or pins and apertures and the like are also withinthe scope hereof. It will also be appreciated that pallet caps 200 mayincorporate or be joined by similar features.

FIG. 19 is a partial, cross-sectional view of a raised flooring system150 including pallet caps 100 over a supporting structure 30 and groundsurface 32. Supporting structure 30 may be a shipping pallet (i.e.,pallet 10), hard cell foam, corrugated metal or other substantiallyraised and strong fill, or may be selected from or combined withsupporting and fill materials described herein below. A stake 34 isplaced through apertures 122 and 124 of edge extension 106 and loweredge plate 120, respectively, and into ground 32. Plastic sheeting 34may alternately be placed beneath supporting structure 30, to reducetransfer of moisture from ground 32 to supporting structure 30 andthereby prevent or reduce molding or other moisture-induced decay.Supporting structure 30 insulates flooring system 150 by raising system150 off ground 32 and by providing insulating sub-floor airspaces 36.Adhesive 38 may optionally be used to further secure pallet caps 100with supporting structure 30. Adhesives include conventional tapes orglues, along with naturally occurring materials such as mud or tree sap.It will be appreciated that raised flooring system 150 may include anynumber of pallet caps 100, with stakes 34 selectively placed to bestsecure flooring system 150 to ground 32. It will also be appreciatedthat pallet caps 200 may substitute for or combine with caps 100 inflooring system 150.

FIG. 20 is a cross-sectional view of a raised flooring system 152,illustrating joining of two pallet caps 100/200 over supportingstructures 40 filled with debris 42. In one aspect, structures 40 arelarge boxes, for example, cardboard boxes, filled with dirt, plasticdebris, cloth debris, paper waste or other refuse. Debris 42 bothprovides support to structures 36 and caps 100/200 and insulatesflooring system 152. Pallet caps 100/200 may be joined together withbolts or screws 44 and nuts 46. Stakes 34 (not shown) may also beincorporated as necessary to stake system 152 to a ground surface.

FIG. 21 is a cross-sectional view of raised flooring system 150 (FIG.19), featuring an alternate multi-unit supporting structure 48.Multi-unit supporting structure 38 may include filled cardboard boxes,bricks or wood, among other options.

FIG. 22 illustrates joining of pallet caps 100/200 over multi-unitsupporting structure 48 via zip tie 20. As described above, an end 21 ofzip tie 20 is fed through a first aperture 122 of edge extension 106 anddown and through a first aperture 124 of lower edge plate 120, whenpallet caps 100 are aligned for connection. End 21 is then fed upthrough a second aperture 124 of lower edge plate 120 and a secondaperture 122 of edge extension 106, and secured. Although FIG. 22illustrates securing of zip tie 20 at or above top surfaces 102 ofpallet caps 100, it will be appreciated that pallet caps 100 mayalternately be joined with zip tie 20 beneath lower edge plate 120, forexample at an easily-accessible edge of raised flooring system 150, orwhen pallet caps 100 are to be joined first and then laid overmulti-unit supporting structure 48.

FIG. 23 illustrates joining and securing pallet caps 100 to lumber 50,for example a structural post, board or framing member. Lumber 50 mayfor example be a vertically-oriented portion of a frame for a housingunit, and as such, pallet caps 100 may form an expandable andcustomizable structural wall 154. Structural wall 154 is shown securedwith lumber 50 via a stake 52; however, other fasteners, such as thosedescribed below, may also be used.

FIGS. 24 and 25 show structural wall 154 respectively attached with apole 54 and timber 56 (for example, a tree trunk or limb), by zip tie20. Other cord-, wire-, or rope-like fasteners may alternately be used.

FIG. 26 is a top, perspective view showing an expandable roofing orceiling system 156 attached with frame members 58. Frame members 58 areshown as lumber forming the partial skeleton of a roof; however, it willbe appreciated that roofing system 156 may alternately be attached withrougher support members, for example, tree limbs. Pallet caps100(1)-100(4) connect with one another and with frame members 58 aspreviously illustrated and described. That is, caps 100 may connect withone another via adhesive, zip ties, bolts, screws or nails, hook andloop fasteners and/or lock and key features. Caps 100 are secured withframe members 58 via screws, bolts, nails, zip ties or other fasteners.Outer surfaces 102 of pallet caps 100 are shown facing outwards (i.e.,atop the roof), in order to provide a smooth roof surface to allowprecipitation to run off without being caught within pallet caps 100.

FIG. 27 shows system 156 affixed to inner surfaces of frame members 58in order to form an expandable ceiling. Outer surfaces 102 of palletcaps 100 face in, in order to provide a smooth ceiling surface free ofledges that might collect dust.

FIGS. 28 and 29 illustrate alternate connection of pallet caps 100. InFIG. 28, caps 100(1) is shown in cross-section through an edge extension106, positioned slightly behind cap 100(2), also shown in cross-sectionthrough an edge extension 106. It will be appreciated that caps 100(1)and 100(2) are positioned such that edge extensions 106 join withcomplimentary edge notches 108; however, for clarity of illustration,complete caps 100(1) and 100(2) are not shown. Pallet caps 100(1) and100)2) are shown extension 106-to-extension 106 in FIG. 29; however, itshould again be noted that the cross-section of pallet cap 100(1) ispositioned behind the cross-section of pallet cap 100(2).

Edge extensions 106 may include a slot 123, in which apertures 122 arelocated. A fastener 125 may be inserted into slots 123 and throughapertures 122, to laterally join pallet caps 100(1) and 100(2) withoutextending above top surfaces 102.

FIGS. 30 and 31 show a flat transport structure or pallet 300 includinga reinforced platform 302 resting upon 5 individual feet or footings 304extending from a bottom surface 306 (FIG. 30). Footings 304 are showntapering to a flat base 308 for contacting ground or other restingsurface. Optionally, base 308 may be textured or formed with surfacefeatures such as divots, grooves and the like, to increase frictionalcontact between footings 304/bases 308 and a ground surface. Likewise,footings 304 may be non-tapering and/or take on a cylindrical or othershape.

Pallet 300 has a top surface 310. FIG. 31 illustrates top surface 310 asa continuous, flat surface; however, it will be appreciated that topsurface 310 may be textured or include bumps, grooves, or other surfacefeatures (e.g., to increase a coefficient of friction of top surface310) as described and illustrated with respect to pallet cap 100,without departing from the scope hereof. Top surface 310 may likewise betreated with a non-slip or non-skid coating.

The effective clear space beneath pallet 300, as provided by height offootings 304, is designed to accommodate powered industrial trucks,forklifts and other transport equipment. The size of platform 302 mayvary along with the number and placement of footings 304 according tointended use. Pallet 300 and/or its components may be made of plastic,wood, metal, composite materials and combinations thereof.

As illustrated in FIG. 31, a barrel housing 312 extends from or isconfigured with an edge 314 of pallet 300. Barrel housing 312 houses acompression-assisted slide bolt assembly 315, for joining pallet 300with an edge of another pallet 300. As further shown in FIGS. 32A-32C,compression assisted slide bolt assembly 315 includes a spring 316 andspring-biased bar 318 housed within a channel 320 of a cylindricalhousing 322. A locking member 324 may be unlocked (e.g., pressed) by akey 326 to release spring 316, allowing the spring to expand and pushbar 318 further out of housing 322. As such, two pallets 300 may bealigned edge-to-edge, with barrel housing(s) 312 of one pallet 300aligning with edges 314, between or proximate barrel housing(s) 312 ofthe other pallet. Once barrel housings 312 of independent pallets 300are aligned, key 326 may be actuated to release spring-biased bars 318and join pallets 300 through channels 320.

FIGS. 33, 34 and 37 illustrate a two-pallet assembly 328. Two pallets300(1) and 300(2) are shown joined perpendicular to one another. It willbe appreciated that slide-bolt assembly 314 and barrel extensions 312create a hinge 330 between pallets 300(1) and 300(2), such that an angleα between pallets 300(1) and 300(2) may be varied. For example, as shown(in less detail) in FIG. 37, pallets 300(1) and 300(2) are joinedin-plane to form a 180° angle α. Such pallet orientation may bedesirable when a pallet assembly 328 or an extended pallet assembly isto serve as a raised floor, structural wall, ceiling or roofingcomponent.

Edges 332, adjacent and opposite edges 314 of pallets 300, form one ormore slide-bolt housings 334 and lock bar slots 336. Lock bar slots 336accept fins 338 of a lock bar 340 when inserted as shown by arrows 341.Lock bar 340 is shown from the top in FIG. 35 and from the bottom, inFIG. 36. Fins 338 of lock bar 340 form apertures 342. When fins 338 areinserted into slots 336, apertures 342 align with channels 344 of slidebolt housings 334, such that when actuated by key 326, compressionassisted slide-bolts 315 secure lock bar 340 in place. Additionalpallets, such as pallet 300(3), may join with pallets 300(1) and 300(2)via lock bars 340 to form a crate assembly 346, as shown in FIG. 38 andexploded FIG. 39.

In one aspect, shown in FIGS. 38 and 39, crate assembly 346 is formedwith bottom surfaces 306 facing outward, such that crate assembly 346may rest upon footings 304 regardless of which pallet 300 faces ground.Alternately, footings 304 may be sized and tapered such that crateassembly 346 may be formed with one or more top surfaces 310 facingoutward, to form one or more flat sides. This may be desirable whencrate assembly 346 is used as a step or seat, solely or in addition touse as a storage crate, or when multiple crate assemblies 346 are to betightly packed together. It will be appreciated that regardless oforientation, key 326 may be used to lock slide-bolt assemblies 314 inplace, to protect contents of crate assembly 346 from theft.

As shown in FIG. 39, three two-pallet assemblies 328(1)-328(3) (FIGS. 33and 34) combine, for example as indicated by arrows 348, to form crateassembly 346 (hereinafter, also referred to as crate 346). Crate 346 isheld together by a series of additional compression assisted slide-bolts314 placed with slide bolt housings 334, in conjunction with multiplelock bars 340 that join two-pallet assemblies 328 in a perpendiculararrangement. A bottom surface 350 of lock bars 340 forms a wedge to fitan angle β between edges 332 of adjacent pallets 300. Whereas hinge 330permits relative movement of pallets 300, the wedge shape and fins oflock bars 340 “lock” pallets 300 in place perpendicular to one another.Lock bars 340 facilitate transferal of vertical and horizontal loads topallets 300 when joined to form crate 346. This load transferal isaccomplished by feeding lock bars 340 into slots 336, which as notedabove are punctured by compression assisted slide-bolts 314. The FIG.38, 39 arrangement of three two-pallet assemblies 328 combining to formcrate 346 is one possible volumetric configuration of multipletwo-pallet assemblies 328. Other configurations of additional two-palletassemblies, for example to form stairs, joined seating and otherstructures, are within the scope hereof.

FIG. 40 illustrates an expandable flooring system 354 composed ofpallets 300(1)-300(8) and associated fasteners. It will be appreciatedthat additional pallets 300 and associated fasteners may be added,without departing from the scope hereof. Size and shape of edges 332 ofpallets 300 permit fit of lock bars 340 therebetween, when pallets 300are oriented in-plane. Compression assisted slide-bolts 340 lock pallets300 together at barrel extensions via slots 336 (and further via slidebolts 314 placed within slide bolt housings 334 and through apertures342 of fins 338). Compression assisted slide-bolts 314 and lock bars 340facilitate the configuration of multiple two-pallet assemblies 328and/or multiple single pallets 300 as expandable flooring system 354 ofa variety of shapes and sizes. Flooring system 354 may thus becustomized to best fit the shape and size of a building, such as arefugee housing unit in the field, to form a raised floor.

FIGS. 41-44 are cross-sectional views through various locations onpallet 300, as also shown in FIG. 47. FIG. 41 is a cross-sectional viewthrough line A-A, FIG. 30, illustrating barrel housing 312 and lock barslot 336, at opposing edges 314 and 332. FIG. 42 shows pallet 300through line B-B of FIG. 33, which intersects slide bolt housing 334.

FIG. 43 is a cross-sectional view of pallet 100 through line C-C of FIG.34, which in this case cuts through an adjustable central footing 356.Adjustable footing 356 is also illustrated in FIGS. 44-46, which shouldbe viewed together with FIG. 46 and the following description. It willbe appreciated that any of footings 304 of pallet 300 may be anadjustable footing such as footing 356. Adjustable footing 356 featuresa collar 358 extending from a bottom surface 360 of base 308. Collar 358fits with and swivels/rotates upon a ball end 362 of a threaded ball pin364. A pin end 366 of ball pin 364 fits within a threaded base 366,holding threaded ball pin 364 stationary. It will be appreciated thatheight of adjustable footing 356 may be adjusted by screwing ball pin364 in or out of threaded base 366. Vertical position and angle ofadjustable footing 356 may therefore be customized to best fit asurface. This customization may be especially helpful on uneven ground,allowing for creation of a level raised flooring system with reducedsite preparation.

FIG. 48 illustrates a pallet 300 supporting cargo 60. Cargo 60 may beboxed or un-boxed. FIG. 49 schematically shows a person 70 standing atoppallet 300, and illustrates relative size of pallet 300 relative toperson 70, although this may vary. FIG. 50 illustrates an expandableflooring system 368 within a shelter 80. Expandable flooring system 368is shown with 12 interconnected pallets 300 joined with bottom surfaces310 facing up to form a smooth floor. It will be appreciated that morepallets, less pallets, or alternate configurations of pallets may formexpandable flooring system 368.

FIGS. 51-55 show interconnection of alternately configured pallets 400.Features of pallets 300 and pallets 400 may be swapped, interchangedand/or combined without departing from the scope and spirit of theinventions disclosed herein. Therefore, similar features of pallets 300and 400 are given like numbering within different series (300 and 400).

Pallets 400 include a reinforced platform 402, with a plurality ofindividual feet or footings, generally designated as footings 404,extending from a bottom surface 406 thereof. Footings 404 includetapering, cylindrical feet 405, tapering, rounded rectangular feet 407and a central, tapering, rounded square foot 309, specifically labeledin FIGS. 52, 54 and 55. All footings 404 are shown with circulardepressions or apertures 411 within a base 308. Depressions 411 increasesurface area contact and friction between footings 404 and a groundsurface, and may therefore aid in securing pallets 400 with ground.Depressions 411 may likewise be formed within bottom surface 406. Inaddition to increasing contact area with a ground surface and frictionalcontact with ground, depressions 411 may allow for in-packing of asupporting or insulating material disposed between pallet 400 and theground, or provide insulating air spaces. Depressions 411 also reducematerial required to manufacture pallet 400, thereby reducing directcost, pallet 400 weight and shipping-related costs. Where replacing orcombining with depressions 411, apertures 411 prevent moistureaccumulation atop pallets 400.

As shown in FIG. 51, pallets 400 may be configured as a crate 446 withbottom surfaces 406 facing outward. However, crate 446 may also beformed with one or more pallets 400 facing inward, such that a smoothtop surface 410 forms at least one face of crate 446. Smooth outer facesmay be desirable where crate 446 is to serve as a seat, step or table inaddition to a lockable storage container.

FIG. 52 illustrates bottom-to-top lateral connection between twopallets, 400(1) and 400(2). Bottom surface 406 of pallet 400(1) joinsadjacent top surface 410 of pallet 400(2), via complementary extensions412 having channels 420 formed therein. As shown, extension 412(1) ofpallet 400(1) fits between extensions 412(2) and (3) of pallet 400(2),such that aligned channels 420 form a continuous channel throughadjoined edges 414 of pallets 400(1 and 400(2).

FIG. 53 illustrates top surface 410-to-top surface 410 lateralconnection of pallets 400(1) and 400(2). Here, extension 412(4) ofpallet 400(1) fits between extensions 412(2) and 412(3) of pallet400(2), with extension 412(1) fitting with an opposing side of extension412(3) of pallet 400(2). One or more slide bolts secures pallets 400(1)and 400(2) together. For example, slide bolt 415 fits within adjacentchannels 420 of extensions 412(2) and 412(4), and pierces channel 420 ofextension 412(2) to connect with a washer and security screw assembly417 on an opposite side (bottom side 406) of pallet 400(2).

FIGS. 54 and 55 illustrate connection of pallets 400(1) and 400(3) incrate 446 of FIG. 51. Once pallets 400(1) and 400(3) are fittedtogether, slide bolt 415 is inserted into channel 420 of pallet 400(1),as indicated by directional arrow 421 (FIG. 54). Slide bolt 412 is thenadvanced forward and rotated such that a head 419 of slide bolt 415 fitswith a notch 423 formed within extension 412 and normal to channel 420(see arrows 425 and 427, FIG. 55). Washer and security screw assembly417 is connected with bolt head 419 to secure slide bolt 415 withinaligned channels, from outside of crate 446. It will be appreciated thatmultiple slide bolts 415 may be used to secure crate 446 together viamultiple channels 420. Each slide bolt 415 connection may secure twopallets 400 together in two axes. When in crate 446 form, the slide bolt415 connections work together to constrain the third axis of every otherjoint of crate 446. For example, as shown in FIG. 55, slide bolt 415 andwasher and security screw assembly 417 prevent movement of pallet 400(1)along the x axis and prevent movement of pallet 400(3) along the y axis.Slide bolts 415 and washer and security screw assemblies 417 connectingother pallets 400 of crate 446 prevent movement along a z axis (notshown), such that crate 446 is fully secured in place.

FIGS. 56-58 schematically illustrate conservation of body heat byraising a person off the ground when sleeping. A person 90 sleepingdirectly on a ground surface 92 suffers conductive heat loss as bodyheat (generally indicated by lines 93) flows away from the body intoground 92, as indicated by heat-flow arrows 94. A blanket 95 coveringthe body cannot prevent heat loss into ground 92. Moisture 96 withinground 92 may further chill person 90, resulting in even greater loss ofbody heat. When person 90 is raised off the ground atop a flooringsystem provided by pallets cap 100/200 or pallets 300/400, contact withmoisture 96 and loss of body heat is reduced. By placing the flooringsystem within a structure, such as structure 80 (FIG. 50), an insulativeair cavity 98 is formed beneath pallet caps 100/200 or pallets 300/400and between walls 82 of structure 80 (which is for example a refugeehousing unit). Exterior airflow indicated by arrows 99 is blocked fromthe interior of structure 80, and therefore, airflow beneath pallet caps100/200 or pallets 300/400 is reduced, thus mitigating convective heatloss in addition to conductive loss of body heat.

Shipping pallet caps 100/200 and pallets 300/400 may be manufactured byinjection molding a molten material, such as plastic, into a mold andallowing the material to set. Caps 100/200 and pallets 300/400 mayalternately be made by structural foam injection molding, by heatforming, vacuum forming, by rotocasting or rotationally molding, byshaping and compressing a malleable material such as water-resistantpaper (e.g., cardboard) or by casting or welding metal forms. However,any method of manufacture that yields a shipping pallet or pallet cap asdisclosed herein may be used to form caps 100/200 or pallets 300/400.

In one aspect, a method of manufacturing a pallet cap includes forming areinforced platform including a top surface, an opposing bottom surfaceand four edges, each edge including at least one edge extension, atleast one edge notch and sidewalls separating and defining adjacentnotches and extensions. Each extension includes (a) a horizontal plateextending from and in the plane of the top surface of the platform, and(b) a downwardly-extending outer wall at a distal end of the horizontalplate, the downwardly-extending outer wall forming an obtuse angle witha bottom surface of the horizontal plate and relative to the bottomsurface of the platform. Each edge notch includes a rear retaining wallextending downward from the platform at an obtuse angle relative to theplatform, and a lower edge plate extending outward from a bottom portionof the rear retaining wall.

While the present disclosure generally discusses multipurpose palletcaps and shipping pallets, and manners in which multiple pallets/capsmay be assembled to produce secure crates, expandable flooring andshelter systems, it is to be appreciated that various types of fasteningmechanisms and configurations of pallets/caps may be used to achievealternate forms. In addition, features disclosed in reference to palletsmay be incorporated into pallet caps, and vice versa, without departingfrom the scope hereof. In particular, pallet caps disclosed herein maybe interconnected to form a secure crate, a stair step structure orother geometric configurations as described above with respect toshipping pallets, and via extensions, notches and fasteners disclosedwith respect to shipping pallets, and vice versa. Furthermore, changesand modifications may be made to the structures and methods disclosedherein without departing from the spirit and scope of this invention.

Combinations of Features

Features described above as well as those claimed below may be combinedin various ways without departing from the scope hereof. The followingexamples illustrate possible, non-limiting combinations of features ofthe inventions described above. It should be clear that many changes andmodifications may be made to the systems and methods described abovewithout departing from the spirit and scope of this invention:

(a) A pallet cap for covering and connecting with at least one palletincludes a reinforced platform having a flat top surface and a bottomsurface opposite the top surface. Four peripheral edges connect the topand bottom surfaces, three or more of the edges forming at least oneedge extension continuing outward from the reinforced platform, and atleast one edge notch proximate and recessed from the at least one edgeextension. A plurality of retaining walls extend downward at an obtuseangle from the bottom surface of the platform and define an innermostsurface of the edge notches, proximate a junction of the platform andthe edge extensions, for securing the pallet cap over a shipping pallet.

(b) In the cap denoted as (a), the edge extensions and edge notches maybe shaped to fit, respectively, with corresponding edge notches and edgeextensions of a second pallet cap.

(c) In the cap donated as (a) or (b), the edge notches may each includea lower edge plate extending horizontally from one of the retainingwalls, for supporting an edge extension of a second pallet cap, when thesecond pallet cap joins with the pallet cap.

(d) In the cap denoted as (a)-(c), the edge extensions and edge notchesmay form a height of the pallet cap.

(e) In the cap denoted as (a)-(d), the edge extensions may include ahorizontal plate extending outward from the top surface of the platformand in the plane of the top surface, and downwardly extending outerwalls having a length substantially equal to a length of the retainingwalls of the edge notches, such that top surfaces of the pallet cap anda second pallet cap are level when the pallet caps connect with the edgeextensions of the pallet cap resting upon the lower edge plates of theedge notches of the second pallet cap.

(f) In the cap denoted as (a)-(e), a plurality of the edge extensionsand a plurality of the lower plate extensions may have at least oneaperture therethrough.

(g) In the cap denoted as (a)-(f), apertures of the edge extensions andapertures of lower plate extensions of the edge notches may be placed anequal distance from a horizontal sidewall separating and defining theedge extensions or the edge notches, such that apertures of the plateextensions align with apertures of lower plate extensions of a secondpallet cap, when the pallet cap and second pallet cap are connected viaedge extensions of the pallet cap resting within edge notches and uponlower edge extensions of the second pallet cap.

(h) In the cap denoted as (a)-(g), apertures through edge notches/lowerplate extensions and edge extensions may be sized to fit a fastenerselected from the group of a screw, a bolt, a stake, a zip tie, cord,wire, rope, twine or other string-like fastener.

(i) In the cap denoted as (a)-(h), one or more sections of hook-and-loopfastener may be disposed with a top surface of the edge extensions(e.g., proximate the apertures, if included), such that edge extensionsof the pallet cap and edge extensions of a second pallet cap may bejoined with a complementary strip of hook-and-loop fastener, tolaterally secure the pallet cap and the second pallet cap together.

(j) In the cap denoted as (a)-(i), the flat top surface may include anon-skid treatment.

(k) In the cap denoted as (a)-(j), a fourth of the pallet cap edges mayhingedly join with a first connected pallet cap having (a) edgeextensions continuing outward from a reinforced platform, (b) edgenotches recessed from the edge extensions and (c) a plurality ofretaining walls extending downward from a bottom surface of theconnected pallet cap and defining the edge notches, along at least twosides of the connected pallet cap.

(l) In the cap denoted as (k), the pallet cap may hingedly join with asecond connected pallet cap at an edge opposite the junction of thepallet cap and the first connected pallet cap, the pallet cap. The firstconnected pallet cap and the second connected pallet cap may be foldablesuch that a bottom surface of the first connected pallet cap folds ontothe top surface of the pallet cap, and a top surface of the secondconnected pallet cap folds onto the top surface of the first connectedpallet cap to provide a tri-pallet cap assembly having a foldedfootprint equal to the footprint of the pallet cap.

(m) In the cap denoted as (a)-(l), the pallet cap may include at leastone outer notched corner formed by distal edge extensions of edgesmeeting perpendicular to one another.

(n) An expandable raised flooring system may include a plurality ofpallet caps, each having (a) a reinforced platform with a flat topsurface and a bottom surface opposite the top surface, and (b) fourperipheral edges, three or more of which form at least one edgeextension and at least one edge notch having rear retaining wallsextending downward from the bottom surface of the pallet cap, forfitting about a shipping pallet and/or raising the cap above a groundsurface. Edge extensions of a first of the plurality of pallet caps mayfit within edge notches of a second of the plurality of pallet caps, toconnect the first and second caps.

(o) In the system denoted as (n), each of the edge notches may include alower edge plate extending horizontally outward from a distal end of therear retaining walls.

(p) in the systems denoted as (n) and (o), each of the edge extensionsmay include a horizontal plate extending outward from the top surface ofthe reinforced platform, and an outer wall extending downward from adistal end of the horizontal plate; such that the outer walls of theedge extensions of the first cap fit against the rear retaining walls ofthe second cap and atop a/the lower edge plate of the second cap, whenthe first and second caps are aligned together.

(q) In the systems denoted as (n)-(p), horizontal plates of the edgeextensions and lower edge plates of the edge notches may include a pairof equally-spaced apertures.

(r) In the systems denoted as (n)-(q), apertures within horizontalplates of the edge extensions and apertures of lower edge plates of theedge notches may align with apertures within corresponding edgenotches/lower edge plates and edge extensions/horizontal plates of thesecond cap, when the edge extensions of the first cap fit within theedge notches of the second cap, to facilitate fixation of the first andsecond caps via a fastener selected from the group of a screw, a bolt, astake, a zip tie, cord, wire, rope, twine or other string-like fastener.

(s) A method of converting shipping pallet caps into raised flooring,may include positioning a plurality of pallet caps over a supportingsurface; interconnecting the pallet caps via complementary lock and keyfeatures of the pallet caps; providing a plurality of apertures throughthe pallet caps, to prevent moisture accumulation atop the pallet capsand to secure the interconnected pallet caps together via fasteners; andproviding a non-skid top surface on each pallet cap, to prevent users ofthe raised flooring system from slipping.

(t) In the method denoted as (s), the lock and key features may includeedge extensions and edge notches of complimentary size and shape.

(u) In the methods denoted as (s) and (t), the pallet caps may beconnected together via fasteners selected from the group of screws,bolts, stakes, zip ties, cord, wire, rope, twine, other string-likefasteners and combinations thereof.

(v) In the methods denoted as (s)-(u), the supporting surface may beselected from the group of a shipping pallet, an insulative material,debris-filled boxes, hard cell foam, timber, compacted soil, lumber andcombinations thereof.

(w) A method of manufacturing a multipurpose transport and flooringstructure may include forming a reinforced platform including a topsurface, an opposing bottom surface and four edges, each edge includingat least one edge extension, at least one edge notch and sidewallsseparating and defining adjacent notches and extensions. Each extensionmay include (a) a horizontal plate extending from and in the plane ofthe top surface of the platform, and (b) a downwardly-extending outerwall at a distal end of the horizontal plate, the downwardly-extendingouter wall forming an obtuse angle with a bottom surface of thehorizontal plate and with the bottom surface of the platform. Each edgenotch may include a rear retaining wall extending downward from theplatform at an obtuse angle relative to the platform, and a lower edgeplate extending outward from a bottom portion of the rear retainingwall.

The invention claimed is:
 1. A pallet cap for covering and connectingwith at least one pallet, the cap comprising: a reinforced platformhaving a flat top surface and a bottom surface opposite the top surface;four peripheral edges connecting the top and bottom surfaces, three ormore of the edges each forming at least one edge extension continuingoutward from the reinforced platform, and at least one edge notchproximate and recessed from the at least one edge extension; and aplurality of retaining walls extending downward at an obtuse angle fromthe bottom surface of the platform and defining an innermost surface ofthe edge notches, proximate a junction of the platform and the edgeextensions, for securing the pallet cap over a shipping pallet; aplurality of the edge extensions and a plurality of the lower plateextensions have at least one aperture therethrough; wherein theapertures of the edge extensions and the apertures of the lower plateextensions are an equal distance from a horizontal sidewall separatingand defining the edge extensions or the edge notches, such thatapertures of the plate extensions align with respective apertures oflower plate extensions of a second pallet cap when the pallet cap andsecond pallet cap are connected via edge extensions of the pallet capresting within edge notches and upon lower edge extensions of the secondpallet cap.
 2. The pallet cap of claim 1, the edge extensions and edgenotches shaped to fit, respectively, with corresponding edge notches andedge extensions of a second pallet cap.
 3. The pallet cap of claim 1,the edge notches each comprising a lower edge plate extendinghorizontally from one of the retaining walls, for supporting an edgeextension of a second pallet cap, when the second pallet cap joins withthe pallet cap.
 4. The pallet cap of claim 3, the edge extensionscomprising a horizontal plate extending outward from the top surface ofthe platform and in a plane of the top surface, and downwardly extendingouter walls having a length substantially equal to a length of theretaining walls of the edge notches, such that top surfaces of thepallet cap and a second pallet cap are level when the pallet capsconnect with the edge extensions of the pallet cap resting upon thelower edge plates of the edge notches of the second pallet cap.
 5. Thepallet cap of claim 1, the edge extensions and edge notches forming aheight of the pallet cap.
 6. The pallet cap of claim 1, the aperturessized to fit a fastener selected from the group of a screw, a bolt, astake, a zip tie, cord, wire, rope, twine or other string-like fastener.7. The pallet cap of claim 1, further comprising one or more sections ofhook-and-loop fastener disposed with a top surface of the edgeextensions, proximate the apertures, such that edge extensions of thepallet cap and edge extensions of the second pallet cap may be joinedwith a complementary strip of hook-and-loop fastener, to laterallysecure the pallet cap and the second pallet cap together.
 8. The palletcap of claim 1, the flat top surface comprising a non-skid treatment. 9.The pallet cap of claim 1, wherein a fourth of the pallet cap edgeshingedly joins with a first connected pallet cap having (a) edgeextensions continuing outward from a reinforced platform, (b) edgenotches recessed from the edge extensions and (c) a plurality ofretaining walls extending downward from a bottom surface of theconnected pallet cap and defining the edge notches, along at least twosides of the connected pallet cap.
 10. The pallet cap of claim 9,wherein the connected pallet cap hingedly joins with a second connectedpallet cap at an edge opposite the junction of the pallet cap and thefirst connected pallet cap, the pallet cap, the first connected palletcap and the second connected pallet cap foldable such that a bottomsurface of the first connected pallet cap folds onto the top surface ofthe pallet cap, and a top surface of the second connected pallet capfolds onto the top surface of the first connected pallet cap to providea tri-pallet cap assembly having a folded footprint equal to thefootprint of the pallet cap.
 11. The pallet cap of claim 1, furthercomprising at least one outer notched corner formed by distal edgeextensions of edges meeting perpendicular to one another.
 12. The palletcap of claim 1, further comprising: at least one additional pallet capforming an expandable flooring system, each additional pallet capincluding: (a) a respective reinforced platform with a second flat topsurface and a second bottom surface opposite the second flat topsurface, and (b) four respective peripheral edges for fitting about ashipping pallet and/or raising the cap above a ground surface, three ormore of which each form at least one second edge extension and at leastone second edge notch having second rear retaining walls extendingdownward from the respective bottom surface of the at least oneadditional pallet cap; wherein the second edge extension of one of theadditional pallet caps fits within the edge notch of the pallet cap, toconnect the pallet cap with the additional pallet cap; wherein each ofthe edge notches of the pallet cap and the second edge notches of theadditional pallet cap includes a lower edge plate extending horizontallyoutward for a distal end of the respective rear retaining wall andsecond rear retaining walls; and wherein each of the edge extensions ofthe pallet cap and the second edge extensions of the additional palletcaps include a horizontal plate extending outward from the respectiveflat top surface and second flat top surface, and an outer wallextending downward from a distal end of the horizontal plate; such thatthe outer walls of the edge extensions of the pallet cap fit against thesecond rear retaining walls and atop the second lower edge plate of oneof the additional pallet caps when the pallet cap and the one of theadditional pallet caps are aligned together the horizontal plates andthe lower edge plates including a pair of equally-spaced apertures;wherein the apertures of the horizontal plates and the apertures of thelower edge plates align when the edge extensions of the pallet cap fitwithin edge notches of the additional pallet cap, to facilitate fixationof the pallet cap and additional pallet cap via a fastener selected fromthe group of a screw, a bolt, a stake, a zip tie, cord, wire, rope,twine or other string-like fastener.